Etching composition

ABSTRACT

This disclosure relates to a method for manufacturing a semiconductor device. The method includes etching a metal film on a semiconductor substrate with an etching composition; and rinsing the etched metal film with a rinse solvent. The etching composition includes at least one acid; at least one compound containing a halide anion, the halide anion being chloride or bromide; at least one compound containing a nitrate or nitrosyl ion; and water.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 13/415,390, filed on Mar. 8, 2012, which claims priority to U.S. Provisional Application Ser. No. 61/451,910, filed on Mar. 11, 2011 and U.S. Provisional Application Ser. No. 61/540,850, filed on Sep. 29, 2011. The contents of the parent applications are hereby incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to semiconductor device manufacturing, and particularly to selective metal wet etching compositions and processes for selectively etching certain metals relative to adjacent structures and materials with those etching compositions. More particularly, the present disclosure relates to aqueous metal etching compositions and processes for use in the presence of one or more of aluminum, and nickel platinum silicides.

BACKGROUND TO THE DISCLOSURE

Integrated circuit manufacture is a multi-step construction process. The process entails repetitive steps of lithography to selectively expose underlying layers, etching of partially or completely exposed layers, and deposition of layers or filling of gaps frequently produced by etching or selective deposition of materials. Etching of metals is a critical process step. Frequently metals must be selectively etched in the presence of other metals, metal alloys, and/or non metal materials without corroding, etching, or oxidizing the adjacent materials. As the dimensions of the features in the integrated circuit become increasingly smaller, the importance of minimizing corrosion, etching, oxidizing, or other damage to adjacent materials and features increases.

The structural features and compositions of the other metals, metal alloys, and non metal materials may vary depending on the particular device so that prior art compositions may not etch the specific metal without damaging the materials in adjacent structures. Combinations of particular adjacent materials may also affect the type and amount of damage produced in an etching step. Thus it is often not obvious which etch composition is appropriate for a given device structure and adjacent materials. It is an objective of this disclosure to provide etching compositions which are suitable to selectively etch selected metals with little or no damage to adjacent materials and structures.

SUMMARY OF THE DISCLOSURE

In one aspect, this disclosure features a composition for etching a metal film (e.g., a Ni or NiPt film). The etching composition contains at least one sulfonic acid, about 0.01% to about 0.5% of at least one halide anion selected from the group consisting of chloride and bromide, at least one compound containing a nitrate or nitrosyl ion, corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and water.

In some embodiments, the etching composition contains A) about 25% to about 95% (e.g., about 60% to about 95%) of at least one sulfonic acid, B) about 0.01% to about 0.5% of at least one halide anion selected from the group consisting of chloride and bromide, C) about 0.1% to about 20% of at least one nitrate anion or a nitrosyl cation, D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) at least about 3% water.

In another aspect, this disclosure features a kit containing at least one sulfonic acid in a first container; at least one compound containing a halide ion in a second container, the halide ion being chloride or bromide; and at least one compound containing a nitrate or nitrosyl ion in a third container. The second container is different from the third container. In some embodiments, the first container is the same as the second or third container. In some embodiments, the first container is different from the second and third containers.

In some embodiments, this disclosure concerns a kit containing, in two or optionally, three containers, the following reagents for forming an etching composition for microelectronic device manufacture: a) at least one sulfonic acid, b) at least one halide anion wherein the halide is selected from the group consisting of bromide and chloride, c) at least one nitrate anion or nitrosyl cation or mixtures thereof, d) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and e) water with the proviso that the at least one nitrate anion or nitrosyl cation and the at least one halide anion are in different containers.

In still another aspect, this disclosure features a method that includes etching a metal film on a semiconductor substrate with an etching composition described herein; and rinsing the etched metal film with a rinse solvent.

In some embodiments, this disclosure concerns a metal etching process that includes (a) providing a semiconductor substrate having a metal film partially or completely exposed to a composition of this disclosure and etchable by it; (b) contacting the metal film to be etched with a composition of this disclosure, and (c) rinsing the etched semiconductor substrate with solvent containing water.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 is representative illustration of a partially completed device just prior to removal of the TiN protective cap and the subsequent etch of NiPt using an etching composition described in this disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The numerical limits (i.e., the upper and lower limits) of the ranges and ratios described herein can be combined. The ranges described herein include all intermediate values within the ranges. In other words, all intermediate values within the ranges described herein are deemed to be disclosed by the disclosure of the ranges. All possible combinations of the various disclosed elements are deemed to be included within the scope of the present disclosure unless specifically excluded.

Unless otherwise stated, % is weight %. All temperatures are measured in Celsius degrees, unless otherwise stated.

The term “essentially free” in the context of this disclosure is defined to mean that none of the specified compounds is intentionally added to a formulation. The specified compounds, if present, are only contaminants in negligible amounts that would not materially affect the properties of a formulation.

In some embodiments, this disclosure concerns an etching composition (e.g., an aqueous composition) containing A) at least one sulfonic acid, B) at least one halide anion selected from the group consisting of chloride and bromide, the at least one halide anion being about 0.01% to about 0.5% of the composition, C) at least one nitrate or nitrosyl ion, D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) water.

One or more sulfonic acids may be employed in the etching compositions of this disclosure. The sulfonic acids may be a solid or a liquid at room temperature as long as the final composition is a homogeneous liquid. Liquid or low melting solid sulfonic acids work effectively.

Preferred sulfonic acids are described by R¹SO₃H (Formula (1)) or by Formula (2). In Formula (1), R¹ can be substituted or unsubstituted C₁-C₁₂ linear or branched alkyl, substituted or unsubstituted C₃-C₁₂ cyclic alkyl, C₁-C₁₂ linear or branched perfluoroalkyl, C₃-C₁₂ cyclic perfluoroalkyl, C₁-C₁₂ linear or branched fluoroalkyl ether, C₃-C₁₂ cyclic fluoroalkyl ether, or substituted or unsubstituted C₇-C₁₂ alicyclic. Examples of substituents include C₁-C₄ alkyl groups, sulfonic acid groups, phenyl groups, C₁-C₄ alkylphenyl groups, hydroxyphenyl groups, and halogen (e.g., fluorine). In Formula (2), R², R³, and R⁴ are independently selected from the group consisting of C₁-C₁₂ linear or branched alkyl, C₃-C₁₂ cyclic alkyl, Cl, Br, F, OH, NO₂, SO₃H, and CO₂H; R⁵=H; and a, b, c, and n are integers selected from the group consisting of 0, 1, 2, and 3 with the relationship a+b+c=n.

In some embodiments, preferred sulfonic acids of Formula (1) are those wherein R¹ is substituted or unsubstituted C₁-C₄ linear or branched alkyl, C₁-C₄ linear or branched perfluoroalkyl, C₄-C₆ linear or branched fluoroalkyl ether, and substituted or unsubstituted C₇-C₁₀ alicyclic groups.

In some embodiments, more preferred sulfonic acids of Formula (1) are those wherein R¹ is substituted or unsubstituted C₁-C₄ linear or branched alkyl or C₁-C₄ linear or branched perfluoroalkyl.

In some embodiments, the most preferred sulfonic acids of Formula (1) are those wherein R¹ is substituted or unsubstituted C₁-C₂ alkyl or C₁-C₂ perfluoroalkyl.

In some embodiments, preferred sulfonic acids of Formula (2) are those wherein R², R³, and R⁴ are C₁-C₄ linear or branched alkyl, Cl, NO₂, OH, SO₃H, F, and CO₂H, where n is an integer selected from the group consisting of 0, 1 and 2.

In some embodiments, more preferred sulfonic acids of Formula (2) are those wherein R², R³, and R⁴ are C₁-C₄ linear or branched alkyl, Cl, NO₂, OH, SO₃H, F, and CO₂H, where n is an integer selected from the group consisting of 0 and 1.

In some embodiments, the most preferred sulfonic acids of Formula (2) are those wherein R², R³, and R⁴ are C₁-C₂ alkyl, Cl, NO₂, OH, F, and CO₂H, where n is an integer selected from the group consisting of 0 and 1.

Examples of sulfonic acids of Formula (1) include, but are not limited to, methanesulfonic acid, trifluoromethanesulfonic acid, ethanesulfonic acid, trifluoroethanesulfonic acid, perfluoroethylsulfonic acid, perfluoro(ethoxyethane)sulfonic acid, perfluoro(methoxyethane)sulfonic acid, dodecylsulfonic acid, perfluorododecylsulfonic acid, butanesulfonic acid, perfluorobutanesulfonic acid, propanesulfonic acid, perfluoropropanesulfonic acid, octylsulfonic acid, pefluorooctanesulfonic acid, methanedisulfonic acid, 2-methylpropanesulfonic acid, cyclohexylsulfonic acid, camphorsulfonic acids, perfluorohexanesulfonic acid, ethanedisulfonic acid, benzylsulfonic acid, hydroxyphenylmethanesulfonic acid, naphthylmethanesulfonic acid, and norbornanesulfonic acids.

In some embodiments, preferred examples of sulfonic acids of Formula (1) include, but are not limited to, methanesulfonic acid, trifluoromethanesulfonic acid, ethanesulfonic acid, trifluoroethanesulfonic acid, perfluoroethylsulfonic acid, perfluoro(ethoxyethane)sulfonic acid, perfluoro(methoxyethane)sulfonic acid, butanesulfonic acid, perfluorobutanesulfonic acid, propanesulfonic acid, perfluoropropanesulfonic acid, methanedisulfonic acid, 2-methylpropanesulfonic acid, camphorsulfonic acids, ethanedisulfonic acid, benzylsulfonic acid, hydroxyphenylmethanesulfonic acid, naphthylmethanesulfonic acid, and norbornanesulfonic acids.

In some embodiments, more preferred examples of sulfonic acids of Formula (1) include, but are not limited to, methanesulfonic acid, trifluoromethanesulfonic acid, ethanesulfonic acid, trifluoroethanesulfonic acid, perfluoroethylsulfonic acid, butanesulfonic acid, perfluorobutanesulfonic acid, propanesulfonic acid, perfluoropropanesulfonic acid, methanedisulfonic acid, 2-methylpropanesulfonic acid, ethanedisulfonic acid, benzylsulfonic acid, hydroxyphenylmethanesulfonic acid, and naphthylmethanesulfonic acid.

In some embodiments, the most preferred examples of sulfonic acids of Formula (1) include, but are not limited to, methanesulfonic acid, trifluoromethanesulfonic acid, ethanesulfonic acid, trifluoroethanesulfonic acid, perfluoroethylsulfonic acid, methanedisulfonic acid, and ethanedisulfonic acid.

Examples of sulfonic acids of Formula (2) include, but are not limited to, benzenesulfonic acid, chlorobenzenesulfonic acids, bromobenzenesulfonic acids, fluorobenzenesulfonic acids, hydroxybenzenesulfonic acids, nitrobenzenesulfonic acids, 2-hydroxy-5-sulfobenzoic acid, benzenedisulfonic acids, toluenesulfonic acids, methylchlorobenzenesulfonic acids, dodecylbenzenesulfonic acids, butylbenzenesulfonic acids, cyclohexylbenzenesulfonic acids, picrylsulfonic acid, dichlorobenzenesulfonic acids, dibromobenzenesulfonic acids, and 2,4,5-trichlorobenzenesulfonic acid.

In some embodiments, preferred examples of sulfonic acids of Formula (2) include, but are not limited to, benzenesulfonic acid, chlorobenzenesulfonic acids, fluorobenzenesulfonic acids, hydroxybenzenesulfonic acids, nitrobenzenesulfonic acids, 2-hydroxy-5-sulfobenzoic acid, benzenedisulfonic acids, toluenesulfonic acids, methylchlorobenzenesulfonic acids, butylbenzenesulfonic acids, and dichlorobenzenesulfonic acids.

In some embodiments, more preferred examples of sulfonic acids of Formula (2) include, but are not limited to, benzenesulfonic acid, chlorobenzenesulfonic acids, fluorobenzenesulfonic acids, hydroxybenzenesulfonic acids, nitrobenzenesulfonic acids, benzenedisulfonic acids, toluenesulfonic acids, and butylbenzenesulfonic acids.

In some embodiments, more preferred examples of sulfonic acids of Formula (2) include, but are not limited to, benzenesulfonic acid, chlorobenzenesulfonic acids, fluorobenzenesulfonic acids, hydroxybenzenesulfonic acids, nitrobenzenesulfonic acids, and toluenesulfonic acids.

In some embodiments, the at least one sulfonic acid includes a mixture of one or more of a first sulfonic acid and one or more of a second sulfonic acid having higher hydrophobicity than the at least one first sulfonic acid. The first sulfonic acid can be selected from the group consisting of acids of Formula (1): R¹SO₃H, where R¹ is an unsubstituted C₁-C₄ linear or branched alkyl.

The second sulfonic acid can be selected from the group consisting of sulfonic acids of formula (2):

In Formula (2), R², R³, and R⁴ are independently selected from the group consisting of C₁-C₁₂ linear or branched alkyl, C₃-C₁₂ cyclic alkyl, Cl, Br, F; R⁵ is H; and a, b, c, and n are integers selected from the group consisting of 0, 1, 2, and 3 with the relationship a+b+c=n.

The second sulfonic acid can also be a compound of Formula (1): R¹SO₃H, where R′ is substituted or unsubstituted C₆-C₁₂ linear or branched alkyl, substituted or unsubstituted C₆-C₁₂ cyclic alkyl, C₁-C₁₂ linear or branched perfluoroalkyl, C₃-C₁₂ cyclic perfluoroalkyl, C₁-C₁₂ linear or branched fluoroalkyl ether, C₃-C₁₂ cyclic fluoroalkyl ether, or substituted or unsubstituted C₇-C₁₂ alicyclic groups. Examples of substituents include, but are not limited to, C₁-C₄ alkyl groups, phenyl groups, and fluorine atoms. In such embodiments, hydrophilic groups (e.g., OH, COOH, SO₃H, or NO₂) can be excluded from substituents suitable for the second sulfonic acid.

Examples of the first sulfonic acids of Formula (1) include, but are not limited to, methanesulfonic acid, ethanesulfonic acid, propanesulfonic acid, and butanesulfonic acid.

Examples of the second sulfonic acids of Formula (2) include, but are not limited to, benzenesulfonic acid, chlorobenzenesulfonic acids, bromobenzenesulfonic acids, fluorobenzenesulfonic acids, toluenesulfonic acids, methylchlorobenzenesulfonic acids, dodecylbenzenesulfonic acids, butylbenzenesulfonic acids, cyclohexylbenzenesulfonic acids, dichlorobenzenesulfonic acids, dibromobenzenesulfonic acids, and 2,4,5-trichlorobenzenesulfonic acid.

Other sulfonic acids suitable as the second sulfonic acid include, but are not limited to, trifluoromethanesulfonic acid, trifluoroethanesulfonic acid, perfluoroethylsulfonic acid, perfluoro(ethoxyethane)sulfonic acid, perfluoro(methoxyethane)sulfonic acid, dodecylsulfonic acid, perfluorododecylsulfonic acid, perfluorobutanesulfonic acid, perfluoropropanesulfonic acid, octylsulfonic acid, pefluorooctanesulfonic acid, cyclohexylsulfonic acid, camphorsulfonic acids, perfluorohexanesulfonic acid, benzylsulfonic acid, naphthylmethanesulfonic acid, and norbornanesulfonic acid,

Preferred sulfonic acids suitable as the second sulfonic acid are those of Formula (1) where R¹ is C₁-C₁₂ linear or branched perfluoroalkyl and those of Formula (2) where R² is C₁-C₁₂ linear or branched alkyl, a is 1, and b and c are 0.

In some embodiments, the at least one sulfonic acid is a naphthalenesulfonic acid, which is optionally substituted with a C₁-C₁₂ linear or branched alkyl group or SO₃H. Examples of substituted or unsubstituted naphthalenesulfonic acid include, but are not limited to, 1-naphthalenesulfonic acid, 2-naphthalenesulfonic acid, 8-methyl-1-napthalenesulfonic acid, 5-methyl-2-napthalenesulfonic acid, 3-methyl-2-napthalenesulfonic acid, 4-methyl-1-napthalenesulfonic acid, and 1,5-naphthalenedisulfonic acid. In some embodiments, the at least one sulfonic acid is a mixture of one or more of the first sulfonic acid of Formula (1) described above and one or more of a second sulfonic acid in which the second sulfonic acid is a naphthalenesulfonic acid optionally substituted with a C₁-C₁₂ alkyl group or SO₃H.

In some embodiments, the first sulfonic acid and the second sulfonic acid are employed in a ratio of from about 10:1 to about 150:1. In some embodiments, the first sulfonic acid and the second sulfonic acid are employed in a ratio of from about 20:1 to about 60:1. In some embodiments, the first sulfonic acid and the second sulfonic acid are employed in a ratio of from about 30:1 to about 40:1.

Performance of the etching compositions described herein can be optimized based on the specific metals present on the device being etched, and the relative hydrophobicity and acidity of the first and second sulfonic acids being employed.

The etching compositions of this disclosure employ one or more sources of halide anion selected from chloride or bromide anions. Mixtures may contain chloride anions from the same or different classes of compounds, bromide anions from the same or different classes of compounds, or may contain both chloride and bromide anions from the same or different classes of compounds.

Any suitable source of ionic chloride or bromide compounds may be employed in the compositions of this disclosure. Care should be taken that the chloride (bromide) does not contain groups unstable to the strong acid conditions. Suitable sources of ionic chloride and bromide include, but are not limited to, hydrogen chloride (bromide), ammonium chloride (bromide), quaternary ammonium chlorides (bromides), amine hydrochlorides (hydrobromides), nitrogen based aromatic and pseudoaromatic hydrochlorides (hydrobromides), phosphonium chlorides (bromides), and metal chlorides (bromides).

In some embodiments, preferred sources of ionic bromides and chlorides include, but are not limited to, hydrogen chloride, hydrogen bromide, ammonium chloride, ammonium bromide, quaternary ammonium chlorides, quaternary ammonium bromides, amine hydrochlorides, amine hydrobromides, nitrogen based aromatic and pseudoaromatic hydrochlorides, and nitrogen based aromatic and pseudoaromatic hydrobromides.

In some embodiments, more preferred sources of ionic bromides and chlorides include, but are not limited to, hydrogen chloride, hydrogen bromide, ammonium chloride, ammonium bromide, quaternary ammonium chlorides, quaternary ammonium bromides, and nitrogen based aromatic and pseudoaromatic hydrochlorides, and nitrogen based aromatic and pseudoaromatic hydrobromides.

In some embodiments, the most preferred sources of ionic bromides and chlorides include, but are not limited to, hydrogen chloride, ammonium chloride, ammonium bromide, and quaternary ammonium chlorides.

Examples of quaternary ammonium chlorides (bromides) include, but are not limited to, those compounds described by R¹R²R³R⁴N⁺Cl⁻ (Br⁻) where R¹, R², R³, and R⁴ independently are substituted or unsubstituted alkyl or phenyl. Examples of R¹, R², R³, and R⁴ include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, octyl, decyl, and phenyl. Examples of substituents include, but are not limited to, fluoride, C₁-C₄ alkyl, and substituted or unsubstituted phenyl. Preferred quaternary ammonium chlorides (bromides) are where R¹, R², R³, and R⁴ are C₁-C₄ alkyl. More preferred quaternary ammonium chlorides (bromides) are where R¹, R², R³, and R⁴ are C₁-C₂ alkyl.

Specific examples of quaternary ammonium chlorides include, but are not limited to, tetramethylammonium chloride, ethyltrimethylammonium chloride, diethyldimethyl ammonium chloride, methyltriethylammonium chloride, tetraethylammonium chloride, phenyltrimethyl ammonium chloride, dimethyldiphenylammonium chloride, benzyl trimethylammonium chloride, tetrapropylammonium chloride, tetrabutylammonium chloride, dimethyldibutylammonium chloride, decyltrimethylammonium chloride, pentyltrimethylammonium chloride, tetra-isopropylammonium chloride, decyltrimethylammonium chloride, 2,2,2-trifluoroethyltrimethylammonium chloride, fluorophenyl trimethyl ammonium chloride, chlorophenyltrimethylammonium chloride, and methylphenyltrimethylammonium chloride. Tetramethylammonium chloride, tetraethylammonium chloride, methyltriethylammonium chloride, ethyltrimethylammonium chloride are preferred from this class of chlorides.

Specific examples of quaternary ammonium bromides include, but are not limited to, tetramethylammonium bromide, methyltriethylammonium bromide, diethyldimethyl ammonium bromide, ethyltrimethylammonium bromide, tetraethylammonium bromide, phenyltrimethyl ammonium bromide, dimethyldiphenylammonium bromide, benzyl trimethylammonium bromide, tetrapropylammonium bromide, tetrabutylammonium bromide, dimethyldibutylammonium bromide, decyltrimethylammonium bromide, pentyltrimethylammonium bromide, tetra-isopropylammonium bromide, decyltrimethylammonium bromide, 2,2,2-trifluoroethyltrimethylammonium bromide, fluorophenyl trimethyl ammonium bromide, chlorophenyltrimethylammonium bromide, and methylphenyltrimethylammonium bromide. Tetramethylammonium bromide, tetraethylammonium bromide, methyltriethylammonium bromide, ethyltrimethylammonium bromide are preferred from this class of bromides.

Examples of amine hydrochlorides (hydrobromides) include, but are not limited to, the reaction products of HCl (HBr) with mono-, di-, and trisubstituted amine compounds, which contain 1 or more amine functional groups. Suitable amine compounds include, but are not limited to, methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, propylamine, dipropylamine, tripropylamine, pyrrolidine, piperidine, ethylmethylamine, ethyldimethylamine, phenylamine, diphenylamine, methyldiphenylamine, dimethylphenylamine, triphenylamine, benzylamine, benzylmethylamine, dibenzylamine, butylamine, dibutylamine, tributylamine, ethylenediamine, triethylenediamine, diethylenetriamine, aniline, dimethylaniline, methylaniline, phenylenediamine, piperazine, and bis-(aminophenyl)methane.

Examples of nitrogen based aromatic and pseudoaromatic hydrochlorides (hydrobromides), include, but are not limited to, the reaction products of HCl (HBr) with pyridine, pyrrole, pyrazole, imidazole, pyrazine, pyrimidine, and their substituted derivatives.

Examples of phosphonium chlorides include tetramethylphosphonium chloride, tetraethylphosphonium chloride, tetrapropylphosphonium chloride, tetrabutylphosphonium choride, dimethyldiethylphosphonium chloride, phenyltrimethylphosphonium chloride, and fluorophenyltrimethylphosphonium chloride.

Examples of phosphonium bromides include tetramethylphosphonium bromide, tetraethylphosphonium bromide, tetrapropylphosphonium bromide, tetrabutylphosphonium bromide, dimethyldiethylphosphonium bromide, phenyltrimethylphosphonium bromide, and fluorophenyltrimethylphosphonium bromide.

Examples of metal chlorides include sodium chloride, lithium chloride, copper chloride, iron chloride, magnesium chloride, nickel chloride, palladium chloride, platinum chloride, tin chloride, and zinc chloride. Examples of metal bromides include sodium bromide, lithium bromide, copper bromide, iron bromide, magnesium bromide, nickel bromide, palladium bromide, platinum bromide, tin bromide, and zinc bromide. For example, the chlorides (bromides) of the specific metal being etched may be added in a buffering approach. The metal chloride may provide some small equilibrium amount of unbound chloride (bromide).

One or more nitrates may be employed from the same or different classes. Similarly, one or more nitrosyl salts from the same or different classes may be employed. Alternatively, a mixture(s) of nitrate(s) and nitrosyl salt(s) from the same or different classes may be employed.

Any suitable source of ionic nitrate anions or nitrosyl salts may be employed in the compositions of this disclosure. Suitable ionic nitrate sources include, but are not limited to, nitric acid, ammonium nitrate, quaternary ammonium nitrates, substituted ammonium nitrates, nitrogen based aromatic and pseudoaromatic reaction products with nitric acid, phosphonium nitrates, and metal nitrates.

In some embodiments, preferred sources of ionic nitrate and nitrosyl salts include, but are not limited to, nitric acid, ammonium nitrate, quaternary ammonium nitrates, nitrogen based aromatic and pseudoaromatic reaction products with nitric acid. More preferred sources of ionic nitrate and nitrosyl salts include, but are not limited to, nitric acid, ammonium nitrate, and quaternary ammonium nitrates. The most preferred sources of ionic nitrate are nitric acid and ammonium nitrate.

Specific examples of quaternary ammonium nitrates include, but are not limited to, tetramethylammonium nitrate, ethyltrimethylammonium nitrate, diethyldimethyl ammonium nitrate, methyltriethylammonium nitrate, tetraethylammonium nitrate, phenyltrimethyl ammonium nitrate, dimethyldiphenylammonium nitrate, benzyl trimethylammonium nitrate, tetrapropylammonium nitrate, tetrabutylammonium nitrate, dimethyldibutylammonium nitrate, decyltrimethylammonium nitrate, pentyltrimethylammonium nitrate, tetra-isopropylammonium nitrate, decyltrimethylammonium nitrate, 2,2,2-trifluoroethyltrimethylammonium nitrate, fluorophenyl trimethyl ammonium nitrate, chlorophenyltrimethylammonium nitrate, and methylphenyltrimethylammonium nitrate. Tetramethylammonium nitrate, tetraethylammonium nitrate, methyltriethylammonium nitrate, ethyltrimethylammonium nitrate are preferred from this class of nitrates.

Examples of substituted ammonium nitrates include, but are not limited to, the reaction products of nitric acid with mono-, di-, and trisubstituted amine compounds, which contain 1 or more amine functional groups. Suitable amine compounds include, but are not limited to, methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, propylamine, dipropylamine, tripropylamine, pyrrolidine, piperidine, ethylmethylamine, ethyldimethylamine, phenylamine, diphenylamine, methyldiphenylamine, dimethylphenylamine, triphenylamine, benzylamine, benzylmethylamine, dibenzylamine, butylamine, dibutylamine, tributylamine, ethylenediamine, triethylenediamine, diethylenetriamine, aniline, dimethylaniline, methylaniline, phenylenediamine, piperazine, and bis-(aminophenyl)methane.

Examples of nitrogen based aromatic and pseudoaromatic reaction products with nitric acid, include, but are not limited to, the reaction products of nitric acid with pyridine, pyrole, pyrazole, imidazole, pyrazine, pyrimidine, and their substituted derivatives.

Examples of phosphonium nitrates include tetramethylphosphonium nitrate, tetraethylphosphonium nitrate, tetrapropylphosphonium nitrate, tetrabutylphosphonium nitrate, dimethyldiethylphosphonium nitrate, phenyltrimethylphosphonium nitrate, and fluorophenyltrimethylphosphonium nitrate.

Examples of metal nitrates include sodium nitrate, lithium nitrate, copper nitrates, iron nitrates, magnesium nitrate, nickel nitrate, palladium nitrate, platinum nitrate, tin nitrate, and nitrate. While these compounds can be employed in the etching compositions described herein, the use of metal nitrates are not preferred in semiconductor applications because of the potential for contamination of the semiconductor device.

Suitable nitrosyl salts include nitrosyl chloride, nitrosyl bromide, nitrosyl fluoride, nitrosyl tetrafluoroborate, and nitrosyl hydrogen sulfate. Nitrosyl hydrogen sulfate and nitrosyl tetrafluoroborate are preferred. Nitrosyl hydrogen sulfate is more preferred.

Water (preferably deionized water), cations for the nitrate and chloride (bromide), anions for the nitrosyl, and optional additives complete the etching composition of this disclosure. Water is at least about 3% of the etching composition so that the etching occurs and the products are dissolved in the etching composition. The water source may be from the acid, the chloride (bromide) source, the nitrate source, or added additionally to any water provided by those sources.

Without wishing to be bound by theory, it is believed that the nitrate source on reaction with the chloride source in a strongly acidic environment forms the oxidizing NO (nitrosyl) halide intermediate. The nitrosyl cation oxidizes the metals and the free halide ions ionized in the aqueous composition complex the metal ions and assist in their dissolution. The soluble metal salts are believed to be coordination compounds with chloride in the coordination sphere. The water is believed to solubilize the inorganic metal salts. The sulfonic acids are used to maintain a low pH for effective formation of the nitrosyl halide at low concentrations of halide and nitrate, and for assistance in dissolution of the metal salts.

In some embodiments of the disclosure, the aqueous etching composition is essentially free of fluoride anions (i.e., F⁻). In some embodiments of the disclosure, the aqueous etching composition is essentially free of abrasives. In some embodiments of the disclosure, the aqueous etching composition is essentially free of both fluoride anions and abrasives. In some embodiments of the disclosure, the aqueous etching composition is essentially free of aromatic nitro compounds, thiocarbonyl compounds, and/or metal ions (except for those metals being etched).

In some embodiments, the sulfonic acid is about 25%-95% of the aqueous etching composition described herein. In some embodiments, the sulfonic acid is about 60%-95% of the aqueous etching composition. In some embodiments, the sulfonic acid is about 60%-80% of the aqueous etching composition. In some embodiments, the sulfonic acid is about 60%-75% of the aqueous etching composition. In some embodiments, the sulfonic acid is about 65%-95% (e.g., about 70%-95%, about 75%-95%, about 80%-95%, about 85%-95%, or about 90%-95%) of the aqueous etching composition. Without wishing to be bound by theory, it is believed that a strongly acidic environment is needed for the nitrate source and the halide source to form an oxidizing nitrosyl halide intermediate, which is an active ingredient in etching a NiPt film. However, although using a large amount of a nitrate source (e.g., nitric acid) or a halide source (e.g., hydrochloric acid) can provide sufficient acidity to the etching composition, they can overly oxidize the materials (e.g., NiPtSi) adjacent to the NiPt film, thereby damaging the adjacent features. Without wishing to be bound by theory, the inventors discovered that using a relative high amount (e.g., about 60%-95%) of a sulfonic acid and a relatively small amount (e.g., about 0.01%-0.5%) of a halide source and/or a relatively small amount (e.g., about 0.01%-20%) of a nitrate source can maintain the acidity of the etching composition to facilitate the etching of NiPt, while reducing the oxidation of NitPtSi during the etching process.

In some embodiments, the sulfonic acid is about 25%-60% (e.g., about 25-50% or about 30-45%) of the aqueous etching composition described herein.

In some embodiments, the halide anion is about 0.01% to about 0.5% of the aqueous etching composition described herein. In some embodiments, the halide anion is about 0.01% to about 0.3% of the aqueous etching composition. In some embodiments, the halide anion is about 0.01% to about 0.2% of the aqueous etching composition. In some embodiments, the halide anion is about 0.01% to about 0.1% of the aqueous etching composition. Without wishing to be bound theory, the inventors discovered that including about 0.01% to about 0.5% of a halide anion into the aqueous etching composition described herein can significantly reduce Al etching/corrosion and reduce NiPtSi oxidation when the etching composition is used to etch a NiPt film, while still effectively etching the NiPt film.

In some embodiments, the nitrate or nitrosyl ion is about 0.1% to about 20% of the aqueous etching composition described herein. In some embodiments, the nitrate or nitrosyl ion is about 0.5% to about 10% of the aqueous etching composition. In some embodiments, the nitrate or nitrosyl ion is about 0.5% to about 5% of the aqueous etching composition. In some embodiments, the nitrate or nitrosyl ion is about 0.5% to about 2.5% of the aqueous etching composition.

In some embodiments, the nitrate or nitrosyl ion is about 2.5% to about 7% (e.g., about 2.5% to about 6% or about 3% to about 5%) of the aqueous etching composition.

In some embodiments, the water is about 3% to about 60% of the aqueous etching composition described herein. In some embodiments, the water is about 3% to about 40% of the aqueous etching composition. In some embodiments, the water is about 14% to about 40% of the aqueous etching composition. In some embodiments, the water is about 20% to about 35% of the aqueous etching composition.

In some embodiments, the water is about 30% to about 60% (e.g., about 35% to about 50% or about 40% to about 45%) of the aqueous etching composition.

In some embodiments, the aqueous etching composition contains A) about 25% to about 95% (e.g., about 60% to about 95%, about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) at least about 3% (e.g., about 3% to about 60%, about 3% to about 40%, about 14% to about 40%, or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition contains A) about 60% to about 95% (e.g., about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 3% to about 40% (e.g., about 14% to about 40% or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition contains A) about 60% to about 90% (e.g., about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.3% (e.g., about 0.01% to about 0.2% or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.5% to about 10% (e.g., about 0.5% to about 5% or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 3% to about 40% (e.g., about 14% to about 40% or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition contains A) about 65% to about 90% (e.g., about 65% to about 80%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.2% (e.g., about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.5% to about 5% (e.g., about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 14% to about 40% (e.g., about 20% to about 35%) water.

In some embodiments of the disclosure, an aqueous etching composition consists essentially of A) about 25% to about 95% (e.g., about 60% to about 95%, about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) at least about 3% (e.g., about 3% to about 60%, about 3% to about 40%, about 14% to about 40%, or about 20 to about 35%) water. As used herein, the phrase “consisting essentially of” limits an etching composition to the specified materials A)-E) and the materials that do not materially affect the basic and novel characteristics of the composition, i.e., effectively etching a metal film (e.g., a NiPt film) without significantly etching/oxidizing an adjacent material (e.g., Al or NiPtSi). For example, the materials that do not materially affect the basic and novel characteristics of the composition can include an additive (e.g., solvents, carboxylic acids or other complexing agents, anti-corrosion agents, viscosity reducing agents, and surfactants).

In some embodiments, the aqueous etching composition consists essentially of A) about 60% to about 95% (e.g., about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 3% to about 40% (e.g., about 14% to about 40% or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition consists essentially of A) about 60% to about 90% (e.g., about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.3% (e.g., about 0.01% to about 0.2% or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.5% to about 10% (e.g., about 0.5% to about 5% or about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 3% to about 40% (e.g., about 14% to about 40% or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition consists essentially of A) about 65% to about 90% (e.g., about 65% to about 80%, about 70% to about 90%, or about 70% to about 80%) of at least one sulfonic acid (e.g., methane sulfonic acid and/or p-toluene sulfonic acid), B) about 0.01% to about 0.2% (e.g., about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide (e.g., chloride), C) about 0.5% to about 5% (e.g., about 0.5% to about 2.5%) of at least one nitrate anion or a nitrosyl cation (e.g., nitrate), D) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and E) about 14% to about 40% (e.g., about 20% to about 35%) water.

In some embodiments, the aqueous etching composition contains (or consists essentially of) A) about 25% to about 95% (e.g., about 60% to about 95%, about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of methane sulfonic acid, B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of chloride, C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of nitrate, D) corresponding counter ions for the chloride and nitrate anions, and E) at least about 3% (e.g., about 3% to about 60%, about 3% to about 40%, about 14% to about 40%, or about 20 to about 35%) water.

In some embodiments, the aqueous etching composition contains (or consists essentially of) A) about 25% to about 95% (e.g., about 60% to about 95%, about 60% to about 90%, about 60% to about 80%, about 65% to about 95%, about 65% to about 90%, about 65% to about 80%, about 70% to about 95%, about 70% to about 90%, or about 70% to about 80%) of methane sulfonic acid and p-toluenesulfonic acid, B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of chloride, C) about 0.1% to about 20% (e.g., about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 2.5%) of nitrate, D) corresponding counter ions for the chloride and nitrate anions, and E) at least about 3% (e.g., about 3% to about 60%, about 3% to about 40%, about 14% to about 40%, or about 20 to about 35%) water.

The pH of the etching composition described herein ranges from about 2 to less than about 0. A preferred pH is from about 1.5 to less than about 0. A more preferred pH is from about 1 to less than about 0. The most preferred pH is less than about 0. In some embodiments, the pH is from about −2 to about 2. In some embodiments, the pH is from about −2 to about 0.

Optional additives may be employed in all embodiments to optimize performance or lower cost include solvents, carboxylic acids or other complexing agents, anti-corrosion agents, viscosity reducing agents and surfactants. The carboxylic acids can be used to improve the metal ion solubility by complimenting the chloride complexation. The surfactants can be used in their traditional purpose as surface tension modifiers but also as wetting agents to inhibit corrosion on various exposed surfaces such as aluminum, silicon dioxide, silicon nitride, silicide, tungsten, and TiN. The solvents allow modification of the Hansen solubility parameters for the solution to target some organic residue removal and change the oxidation potential of the solution. Additives employed may be mixtures of different types, mixtures of the same class of additive, or mixtures of both the same class and different types of additives. Care should be taken that the additives are stable under the low pH and oxidizing conditions.

In some embodiments, the etching composition described herein includes one or more organic solvents. In some embodiments, the organic solvents suitable for use in the etching compositions described herein exclude stabilizers such as glycols, ethers, and polyols. Examples of specific organic solvents (or stabilizer) that can be excluded from the etching composition include glyme, diglyme, triglyme, crown ethers, ethylene glycol, tripropylene glycol, and propylene glycol methyl ether. In some embodiments, the etching composition can include one or more the excluded solvents described above.

Concentration of the additives may depend on the effectiveness or purpose of the specific additive. The concentration of additional solvents that may be employed can be from about 3% to about 35%. The concentration of carboxylic acids, other chelating agents, viscosity reducing agents, and surfactants can be from about 0.001% to about 10%.

In some embodiments, the formulation is mixed and used immediately after use. In some embodiments, the formulation is mixed and stored for a period of time before use. In some embodiments, the components are divided between one or more of a Formulation A, a Formulation B, and optionally a Formulation C. Formulation A and B and optional Formulation C are mixed to produce an aqueous etching composition of this disclosure.

Thus, in some embodiments, this disclosure concerns a kit comprising, in two or optionally, three containers, the following reagents for forming an etching composition for microelectronic device manufacture: a) at least one sulfonic acid, b) at least one halide anion wherein the halide is selected from the group consisting of bromide and chloride, c) at least one nitrate anion or nitrosyl cation or mixtures thereof, d) corresponding counter ions for the halide and nitrate anions (or nitrosyl cation), and e) water with the proviso that the at least one nitrate anion or nitrosyl cation and the at least one halide anion are in different containers.

In some embodiments, this disclosure concerns a kit comprising, in two, or optionally three, containers, compositions that when mixed form an aqueous etching composition described herein for microelectronic device manufacture. Such an aqueous etching composition can include A) about 25% to about 95% (e.g., about 60% to about 95%) of at least one sulfonic acid, B) about 0.01% to about 0.5% (e.g., about 0.01% to about 0.3%, about 0.01% to about 0.2%, or about 0.01% to about 0.1%) of at least one halide anion selected from the group consisting of chloride and bromide, C) about 0.1%-20% (e.g., about 0.5%-10%, about 0.5%-5%, or about 0.5%-2.5%) of at least one nitrate anion or nitrosyl cation, D) corresponding counter ions for the nitrate and halide anions and nitrosyl cation, and E) at least about 3% water with the proviso that the at least one nitrate anion or nitrosyl cation and the at least one halide anion are in different containers.

In some embodiments, Formulation A contains the halide anion and sulfonic acid and optionally, water, and optional ingredients. Formulation B contains the nitrate or nitrosyl ion and sulfonic acid, and optionally water and optional ingredients. Concentrations of the components of Formulation A and Formulation B are adjusted to yield the concentration desired after mixing Formulations A and B. The specific concentrations will be dependent on the mixing ratio of Formulations A and B. A wide range of mixing ratios may be employed, but could be limited by the amounts of specific component required for the final formulation. A 1:1 mixing ratio is convenient and generally preferred.

For example, a 200 g sample of 90% sulfonic acid, 0.5% HCl, 2% HNO₃, and 7.5% water, can be obtained with a 1:1 mixing ratio with the following formulations A and B:

Formulation A: 1 g HCl, 9 g water, and 90 g sulfonic acid,

Formulation B: 4 g HNO₃, 6 g water, and 90 g sulfonic acid.

The water and sulfonic acid contents in the two formulations may be adjusted somewhat but the adjustment range is limited by the low amount of water and whether or not the HNO₃ and HCl are introduced as aqueous solutions.

The same 90% sulfonic acid, 0.5% HCl, 2% HNO₃, and 7.5% water formulation described above can be obtained using a 1:3 and a 3:1 mixing ratio as follows:

1:3 Ratio:

Formulation A: 1 g HCl, 8 g water, and 41 g sulfonic acid,

Formulation B: 4 g HNO₃, 7 g water, and 139 g sulfonic acid.

3:1 Ratio:

Formulation A: 1 g HCl, 8 g water, and 141 g sulfonic acid,

Formulation B: 4 g HNO₃, 7 g water, and 39 g sulfonic acid.

Alternatively, one of the formulations described in the preceding paragraph can contain only HCl and water. For example, the same 90% sulfonic acid, 0.5% HCl, 2% HNO₃, and 7.5% water formulation described above can be obtained via mixing Formulations A and B below:

Formulation A: 1 g HCl, and 8 g water

Formulation B: 4 g HNO₃, 7 g water, and 180 g sulfonic acid.

Those skilled in the art can easily calculate the amounts of each component necessary for Formulations A and B for each mixing ratio.

This disclosure additionally is concerned with a process for etching metal films. The metal films to be etched include the Noble metals (e.g., Pt, Au, Pd, Ir, Ni, Mo, Rh, and Re), Lanthanide metals (e.g., Erbium, Gadolinium, Ytterbium, Yttrium, Holmium, and Dysprosium), and alloys (e.g. NiPt (3-20%)) thereof.

Materials likely to be integrated into advanced integrated circuit design and exposed to the etching composition which are not desired to be etched include high-k materials (e.g., HfO₂, HfON, and HfSiON), Metal Gate Materials (e.g., TiN, TaN, TiAlN, and W), interstitial layers (e.g., Al₂O₃ and La₂O₅), fill metals (e.g., aluminum), dielectrics (e.g., Si₃N₄ and SiO₂), semiconductors (e.g., p-doped and n-doped Si, Ge, and SiGe), silicides of the metals to be etched (e.g. nickel platinum silicide), contact materials (e.g., NiGe, NiPtGe, and NiInSb), and III-V materials (e.g., InGaAs, InSb, GaP, GaAs, and InP). The etch compositions and processes of this disclosure should be optimized in order to cause minimal or no damage to these films but yet remove the undesired metal.

In some embodiments, the metal etching process described herein concerns the etching of nickel and/or nickel alloys (e.g., a nickel platinum alloy). In some embodiments, the process described herein concerns the etching of nickel platinum in the presence of Al films and/or nickel platinum silicide.

In some embodiments, the metal etching process described herein includes (a) providing a semiconductor substrate having a metal film partially or completely exposed to an etching composition of this disclosure and etchable by it; (b) contacting the metal film to be etched with an etching composition of this disclosure, and (c) rinsing the etched semiconductor substrate with a solvent (e.g., a solvent containing water).

The etching composition can be brought into contact with the semiconductor substrate by any suitable means known to those skilled in the art. Such means include, but are not limited to, immersing the semiconductor substrate in a bath of the etching composition, or spraying or streaming the etching composition onto the semiconductor substrate. The spraying or streaming of the etching composition can terminate once the substrate is covered with the etching composition, or can continue for a portion or all of the time the etching composition is in contact with the semiconductor substrate. Typically the semiconductor substrate and the etching composition can be brought fully into contact in a few seconds. Depending on the specific process, additional etchant may be applied during the etch period or consistently throughout the period.

During the etch period, the process can include or exclude means of agitation. For example, in an immersion embodiment of the process, the etch solution may be circulated or stirred. Alternatively, the substrate can be rotated or moved up and down during the etch. In streaming or spraying embodiments of the process where the semiconductor substrate is positioned horizontally, the substrate can be rotated horizontally. In any of the embodiments, the semiconductor substrate can be vibrated to induce agitation. Those skilled in the art can determine optimum combinations of contacting and agitation means for the specific application.

The etch period typically can run from approximately 30 seconds to about 30 minutes. The time will depend on the thickness of the film being etched, the necessity to avoid deleterious effects on other exposed films, the particular etch composition being employed, the specific contacting means being employed and the temperature employed.

The temperature at which the metal film is etched is typically between 25° C. and 60° C. A preferred temperature range is from about 25° C. to about 50° C. The most preferred temperature range is from about 30° C. to about 50° C. Alternatively, the temperature range can be from about 25° C. to about 80° C. or from about 30° C. to about 60° C.

Subsequent to the etching step, the semiconductor substrate is rinsed with solvent comprising water, preferably deionized water. Any suitable method of rinsing may be employed. Examples include immersion of the semiconductor substrate in stagnant or flowing water, or spraying or streaming water onto the semiconductor substrate. Agitation as described above during the etch period may be employed.

The aqueous based solvent may include additional aqueous soluble organic solvents. If employed the aqueous organic solvent will assist in removing organic residues or speed drying.

Subsequent to the rinsing step, in an optional step, the drying of the semiconductor substrate may be accelerated using a drying means. Examples of drying means include spraying with a non-oxidizing gas such as nitrogen gas, spinning the substrate, or baking on a hot plate or in an oven.

EXAMPLES

The present disclosure is illustrated in more detail with reference to the following examples, which are for illustrative purposes and should not be construed as limiting the scope of the present disclosure. Any percentages listed are by weight (wt %) unless otherwise specified. Controlled stirring during testing was done with a stir bar at 200 rpm unless otherwise noted.

General Procedure 1 Formulation Blending

Samples of etch/etchant compositions were prepared by adding, while stirring, to the calculated amount of ultra pure deionized water (DI water) at least one halide ion source (1), at least one sulfonic acid and at least one nitrate ion or nitrosyl source (2). After a uniform solution was achieved the optional additives (except optional pH adjusting agents), if used, were added. The solution was allowed to equilibrate and the pH of the etch/etchant composition was taken, if needed.

The pH measurements, if needed, were taken at ambient temperature after all components were fully dissolved. All components used were commercially available and of high purity.

General Procedure 2 Etch Test in Beaker

The NiPt patterned wafers, containing materials and features shown in FIG. 1, were diced into test coupons containing these key features for the etch tests. In FIG. 1, WFM is Work Function Metal; PMOS p-type Silicide on Silicon; and NMOS is n-type Silicide on Silicon.

Typically, on the top of NiPt layer, there can be a TiN cap (not shown in Figure) with thickness of around 50-100{acute over (Å)} which can be removed by standard SC1 solution (1:1:5 part in volume 29% NH₄OH:30% H₂O₂:H₂O) at room temperature for around 10 min prior to etch test. The test coupons were held using 4″ long plastic locking tweezers, whereby the coupon could then be suspended into a 500 ml volume glass beaker containing approximately 200 ml's of the etch compositions of the present disclosure. Prior to immersion of the coupon into the etch composition, the composition was pre-heated to the test condition temperature of 30° C.-80° C. with controlled stirring. The etch tests were then carried out by placing the coupon which was held by the plastic tweezers into the heated composition in such a way that the NiPt layer containing side of the coupon faced the stir bar. The coupon was left static in the etch composition for a period of 1 or 2 or 5 minutes while the composition was kept at the test temperature under controlled stirring. Once the coupon was exposed in the composition for the duration of the test, the coupon was quickly removed from the etch composition and placed in a 500 ml plastic beaker filled with approximately 400 ml of DI water at ambient temperature (˜17° C.) with gentle stirring. The coupon was left in the beaker of DI water for approximately 30 seconds, and then quickly removed, and rinsed under a DI water stream at ambient temperature for about 30 seconds. Then the coupon was immediately exposed to a nitrogen gas stream from a hand held nitrogen blowing gun which caused any droplets on the coupon surface to be blown off the coupon, and further to completely dry the coupon device surface. Following this final nitrogen drying step, the coupon was removed from the plastic tweezers holder and placed into a covered plastic carrier with the device side up for short term storage no greater than about 2 hours. The scanning electron microscopy (SEM) images were then collected for key features on the cleaned test coupon device surface.

General Procedure 3 Materials Compatibility Test in Beaker

The blanket TiN on 5000 Å silicon oxide on silicon substrate, NiPtSi on silicon substrate, and pure Al metal on 5000 Å SiO₂ on silicon substrate, NiPtSiC on silicon substrate, NiPtSiGe on silicon substrate, TaN on silicon substrate, HfO₂ on silicon substrate, SiO₂ on silicon substrate, SiN on silicon substrate, and W on 1000 Å silicon oxide on silicon substrate wafers were diced into approximately 1 inch×1 inch square test coupons for the materials compatibility tests. The test coupons were initially measured for thickness or sheet resistance by the 4-point probe, CDE Resmap 273 for metallic film, or by Elipsometry for dielectric film using a Woollam M-2000X. The test coupons were then held using 4″ long plastic locking tweezers, whereby the coupon could then be suspended into a 500 ml volume glass beaker containing approximately 200 ml of the etch compositions of the present disclosure. Due to the reactive nature of the compositions, they may also be formulated into two components that would be mixed together and then heated at point of use (or heated and then mixed with optional heating at point of use) to give the final etching composition. This type of partitioning of the composition is done to separate the reactive chloride and nitrate components to improve shelf and storage life of the etching solutions.

Prior to immersion of the coupon into the etch composition, the composition was pre-heated to the test condition temperature of 30° C.-80° C. with controlled stirring. The materials compatibility tests were then carried out by placing the coupon which was held by the plastic tweezers into the heated composition in such a way that the TiN, NiPtSi, NiPtSiC, NiPtSiGe, TaN, HfO₂, SiO₂, SiN, W or pure Al layer containing side of the coupon faced the stir bar. The coupon was left static in the etch composition for a period of 1 or 2 or 5 or 10 or 30 or 60 minutes while the composition was kept at the test temperature under controlled stirring. Once the coupon was exposed in the composition for the duration of the test, the coupon was quickly removed from the etch composition and placed in a 500 ml plastic beaker filled with approximately 400 ml of DI water at ambient temperature (˜17° C.) with gentle stirring. The coupon was left in the beaker of DI water for approximately 30 seconds, and then quickly removed, and rinsed under a DI water stream at ambient temperature for about 30 seconds. Then the coupon was immediately exposed to a nitrogen gas stream from a hand held nitrogen blowing gun which caused any droplets on the coupon surface to be blown off the coupon, and further to completely dry the coupon surface. Following this final nitrogen drying step, the coupon was removed from the plastic tweezers holder and placed into a covered plastic carrier with the TiN, NiPtSi and pure Al side up for short term storage no greater than about 2 hours. The post-thickness or sheet resistance was then collected on the post-processing test coupon surface by the 4-point probe, CDE Resmap 273 or by Elipsometry for dielectric film using a Woollam M-2000X.

General Procedure 4 Oxidation Analysis

The oxidation and cleaning of the substrates were evaluated using Electron Spectroscopy for Chemical Analysis (ESCA) and a SEM Pad. The profile of the degree of oxidation of the NiPt silicide was measured by ESCA using Ar ion etching at a rate of approximately 10 angstroms/second on a wide area down through the top 130 angstroms of the film. The SEM pad, a 60×100 μm rectangular structure on the die that contained residual NiPt on metal rich Ni_(x)Pt_(y)Si_(z) was used to evaluate the cleaning of the residual NiPt and oxidation of the underlying metal rich silicides.

Formulation Examples and Formulation Examples CFE1-CFE45

TABLE 1 Etching Compositions Total Acid Halide Other Halide Other Nitrate Water in Formula- compound/ Nitric Acid/ Source/ source/ Sulfonic Acid/ Water/other all sources tion # Amount [g] Amount [g] Amount [g] Amount [g] Amount [g] Added [g] (g) FE6 HCl 2.7 HNO₃ 14.29 MSA 183.01 60.89 FE7 HCl 1.08 HNO₃ 1.43 MSA 197.49 60.36 FE8 HCl 1.08 HNO₃ 7.15 MSA 191.77 60.36 FE11 HCl 1.08 HNO₃ 7.15 MSA 168.91 22.86 Water 76.35 FE12 HCl 1.08 HNO₃ 7.15 MSA 138.45 + 44.36 53.32 MSA (100%) FE13 HCl 1.08 HNO₃ 7.15 MSA 85.11 + 28.36 106.66 MSA (100%) FE14 HCl 1.08 HNO₃ 7.15 MSA 31.78 + 12.36 159.99 MSA (100%) FE15 HCl 1.08 HNO₃ 28.57 MSA 170.347 60.36 FE16 HCl 1.08 HNO₃ 57.143 MSA 141.776 60.36 FE17 HCl 0.541 HNO₃ 7.143 MSA 192.317 60.18 FE18 HCl 0.27 HNO₃ 7.143 MSA 192.587 60.09 FE19 HCl 0.27 HNO₃ 28.571 MSA 171.158 60.09 FE21 HCl 0.162 HNO₃ 7.143 MSA 192.695 60.06 FE22 HCl 0.054 HNO₃ 7.143 MSA 192.803 60.02 FE23 HBr 1.847 HNO₃ 7.143 MSA 191.01 60.41 FE26 HCl 0.27 HNO₃ 7.143 MSA 177.46 60.67 PTSA 15.13 FE27 HCl 0.27 HNO₃ 7.143 MSA 186.536 60.325 PTSA 6.051 FE28 HCl 0.27 HNO₃ 7.143 MSA 189.56 60.21 PTSA 3.026 FE29 HCl 0.27 HNO₃ 7.143 MSA 190.587 59.49 OSBA 2 FE30 HCl 0.27 HNO₃ 7.143 MSA 178.9; 55.98 MSA(100%) 6 OSBA 14 FE31 HCl 0.27 HNO₃ 7.143 MSA 191.59 59.79 TFMSA 1 FE32 HCl 0.27 HNO₃ 7.143 MSA 169.587 7.00 Water 60.185 TFMSA 16 FE33 HCl 0.27 HNO₃ 7.143 MSA 178.59 57.69 BSA 14 FE34 HNO₃ 7.143 TMACl 0.3 MSA 186.06 0.446 Water 60.40 PTSA 6.051 FE35 HNO₃ 7.143 NH4Cl 0.16 MSA 186.7 60.19 PTSA 6.051 FE36 HCl 0.27 HNO₃ 28.57 MSA 149.0 22.16 water 75.6 FE37 HCl 0.27 HNO3 7.143 MSA 59.18 52.06 MSA (100%) 23.4 NAP 10 CFE1 HCl 21.62 HNO₃ 5.71 none none none 172.67 water 188.00 CFE2 HCl 21.62 HNO₃ 20.01 none none none 158.37 water 178.00 CFE3 HCl 21.62 HNO₃ 34.29 none none none 144.09 water 168.00 CFE4 HCl 59.46 HNO₃ 5.71 none none none 134.83 water 174.00 CFE5 HCl 59.46 HNO₃ 20.01 none none none 120.53 water 164.00 CFE6 HCl 59.46 HNO₃ 34.29 none none none 106.25 water 154.00 CFE7 HCl 97.30 HNO₃ 5.71 none none none 96.99 water 160.00 CFE8 HCl 97.30 HNO₃ 20.01 none none none 82.70 water 150.00 CFE9 HCl 97.30 HNO₃ 34.29 none none none 68.41 water 140.00 CFE10 HCl 40.54 HNO₃ 12.86 none none none 146.60 water 176.00 CFE11 HCl 40.54 HNO₃ 27.14 none none none 132.32 water 166.00 CFE12 HCl 78.38 HNO₃ 12.86 none none none 108.76 water 162.00 CFE13 HCl 78.38 HNO₃ 27.14 none none none 94.48 water 152.00 CFE14 HCl 21.62 HNO₃ 20.01 TMACl 42.09 none none 116.28 water 135.90 CFE15 HCl 21.62 HNO₃ 20.01 TMACl 84.17 none none 74.21 water 93.83 CFE16 HCl 1.08 HNO₃ 7.15 none none none 191.77 water 194.60 CFE17 HCl 1.08 HNO₃ 198.919 none none none 60.36 CFE18 none HNO₃ 20.01 none none MSA 94.95 85.05 water 119.54 CFE19 HCl 21.62 none none none MSA 104.34 74.04 water 118.96 CFE20 HCl 21.62 HNO₃ 20.01 none none MSA 36.90 121.47 Water 152.16 CFE21 HCl 21.62 HNO₃ 20.01 none none MSA 73.80 84.57 Water 126.33 CFE22 HCl 21.62 HNO₃ 20.01 none none MSA 55.35 103.02 Water 139.24 CFE23 HCl 16.21 HNO₃ 20.01 none none MSA 69.86 93.91 Water 131.08 CFE24 HCl 21.62 HNO₃ 14.29 none none MSA 82.65 81.45 water 124.15 CFE25 HCl 21.62 HNO₃ 14.29 none none MSA 73.80 90.29 Water 130.33 CFE26 HCl 21.62 HNO₃ 7.14 none none MSA 93.35 77.88 Water 121.65 CFE27 HCl 21.62 HNO₃ 7.14 none none MSA 73.80 97.44 water 135.34 CFE28 HCl 21.62 HNO₃ 20.01 TMACl 42.08 none MSA 36.90 79.39 Water 110.08 CFE29 HCl 21.62 HNO₃ 20.01 none none MSA 158.38 67.14 CFE30 HCl 10.81 HNO₃ 20.01 none none MSA 84.38 84.81 water 122.93 CFE31 HCl 10.81 HNO₃ 20.01 none none MSA 65.92 103.26 Water 135.85 CFE32 HCl 10.81 HNO₃ 14.29 none none MSA 97.75 77.16 water 117.58 CFE33 none none TMACl 12.06 TMANO₃ 15.11 MSA 134.29 38.56 Water 78.85 CFE34 HCl 10.81 HNO₃ 14.29 MSA 174.9 63.57 CFE35 HCl 10.81 HNO₃ 1.43 MSA 187.76 63.57 CFE36 HNO₃ 7.15 TMACl 1.20 MSA (100%) 2.145 191.65 CFE37 HCl 1.08 HNO₃ 142.857 MSA 56.062 60.36 CFE38 HBr 9.235 HNO₃ 7.143 MSA 183.622 62.03 CFE39 1.08 HCl; HNO₃ 7.143 MSA 189.93 60.76 1.846 HBr CFE40 HCl 108.11 HNO₃ 24.57 none none none 67.32 water 142.8 CFE41 HCl 0.27 HNO₃ 7.143 none none none 192.59 water 194.90 CFE42 none HNO₃ 28.57 TMACl 4.40 none MSA 142.86 24.17 water 75.60 CFE43 none HNO₃ 7.143 TMACl 4.40 none MSA 180.4 2.06 water 60.32 PTSA 6.051 CFE44 none HNO₃ 42.86 Methylamine none none 73.14 water 86 Hydrochloride 4.0 tetra- 80.0 ethylene glycol dimethyl ether CFE45 HCl 5.41 HNO₃ 14.29 none none MSA 157.14 13.16 water 68 10 tetra- ethylene glycol dimethyl ether Notes: Hydrochloric acid (HCl) is a 37% hydrochloric acid solution; Hydrobromic Acid (HBr) is a 48% acid solution; Methylamine Hydrochloride is a >98% solid; Nitric acid (HNO₃) is a 70% nitric acid solution; MSA is methanesulfonic acid which is a 70% methanesulfonic acid solution unless otherwise noted; PTSA is a 67% p-toluenesulfonic acid aqueous solution; BSA is a benzenesulfonic acid monohydrate solid; OSBA is an o-sulfonate benzoic acid solid dried under heat and vacuum to remove any water; TFMSA is a neat liquid containing trifluormethanesulfonic acid; NAP is 1,5-naphthalenedisulfonic acid tetrahydrate; TMACl is a tetramethylammonium chloride anhydrous solid; TMANO₃ is a tetramethylammonium nitrate anhydrous solid. The amount for each component in this table refers to the amount of the component as added to the composition, not the amount of the active ingredient in the component. For example, 2.7 g of HCl in FE6 refers to 2.7 g of a 37% hydrochloric acid solution, not 2.7 g of pure HCl.

Examples C1-C16

NiPt etch responses were measured on patterned substrates containing dense RPG (replacement gate) gate line arrays with exposed TiN, Al, SiON, SiO₂, and NiPtSi layers as shown in FIG. 1. These dense RPG gate line arrays were covered by NiPt layer with thickness of 100-350 {acute over (Å)}. The substrates may or may not have been exposed to rapid thermal annealing (RTA) process prior to etch. NiPt etch tests were performed as outlined in General Procedure 2. Aluminum corrosion responses were measured on commercial pure Al blanket wafer. Aluminum corrosion tests were performed as outlined in General Procedure 3. Substrate chips were immersed into the etch compositions heated to 50° C. for 1 or 2 minutes for NiPt etch tests and for 1 or 2 or 5 or 10 minutes for Al corrosion tests. Etch efficiency was gauged by the amount of NiPt residues left on top of dense gate line arrays and aluminum corrosion by the etch rate of aluminum and the severity of pitting on aluminum surface. Results are given in Table 2.

TABLE 2 NiPt Etch and Al Corrosion Results for Formulations CFE1-CFE13, CFE 16, CFE17, and CFE41 Al Corrosion Calculated NiPt Etch and pitting Example # Formulation # pH (1 to 10) (1 to 10) C1 CFE1 −0.15 1 10 C2 CFE2 −0.35 1 9 C3 CFE3 −0.48 5 7 C4 CFE4 −0.53 4 8 C5 CFE5 −0.62 9 6 C6 CFE6 −0.70 10 2 C7 CFE7 −0.72 10 3 C8 CFE8 −0.79 10 1 C9 CFE9 −0.84 10 1 C10 CFE10 −0.45 3 9 C11 CFE11 −0.56 9 6 C12 CFE12 −0.68 10 3 C13 CFE13 −0.74 10 2 C14 CFE16 0.34 2 9 C15 CFE17 −1.05 10 1 C16 CFE41 0.38 1 10 Note to NiPt etch rating: 1 = no NiPt removed; 10 = all of the NiPt was removed Note to Al corrosion and pitting rating: 1 = Al layer was completely removed or High Al ER or Severe Al pitting; 10 = Low Al ER and no Al pitting

As shown in Table 2, the formulations CFE1-CFE13, CFE16, CFE 17, and CFE41 could not achieve an adequate NiPt etch rate and yet have minimal aluminum corrosion.

Examples C17-27 and Examples 1-8 Evaluation of Corrosion Inhibitor and Etch Agent

Various materials were screened for their ability to inhibit Al corrosion in etch compositions of this disclosure, especially sulfonic acids. The substrate tested for aluminum corrosion is commercial pure Al blanket wafer. Sample coupons were treated as described in General Procedure 2 and 3. All NiPt etch tests were carried out @ 50° C. with 2 minutes immersion time and all aluminum corrosion tests were carried out @ 50° C. with 5 or 10 minutes immersion time. The aluminum coupon surfaces were examined for blanket etch rate and signs of pitting. Results are listed in Table 3.

TABLE 3 NiPt Etch and Al Corrosion Results for Formulations Total Total H⁺ Total Cl⁻ NO₃ ⁻ Total NiPt Al Al Example Formula- Sulfonic Acid/ Amount Amount Amount Water Etch Corrosion Pitting # tion # Amount[g] [moles] [moles] [moles] Moles (1 to 10) (1 to 10) (1 to 10) C17 CFE2 none 0.441 0.219 0.222 9.89 1 4 10 C18 CFE16 none 0.090 0.011 0.0794 10.811 2 9 10 C19 CFE17 none 2.22 0.011 2.21 3.35 10 1 9.5 C20 CFE20 MSA 36.90 0.710 0.219 0.222 8.46 6 5 8 C21 CFE21 MSA 73.80 0.979 0.219 0.222 7.02 10 7 9 C22 CFE22 MSA 55.35 0.845 0.219 0.222 7.73 8 4 8 C23 CFE41 none 0.0821 0.0027 0.0794 10.83 1 10 10 C24 CFE42 MSA 142.86 1.399 0.0402 0.3175 4.2 10 3 5 C25 CFE43 MSA 180.4 1.418 0.0402 0.0794 3.35 N/A 2 2 PTSA 6.051 C26 CFE44 none 0.476 1.186 0.476 4.78 4 1 1 C27 CFE45 MSA 157.14 1.360 0.0549 0.159 3.78 N/A 3 4 1 FE7 MSA 197.49 1.47 0.011 0.0158 3.35 10 9.5 8 2 FE8 MSA 191.77 1.49 0.011 0.0794 3.35 10 9 10 3 FE16 MSA 141.78 1.68 0.011 0.635 3.35 10 7.5 9.5 4 FE18 MSA 192.59 1.486 0.0028 0.0794 3.34 9.5 9 10 5 FE27 MSA 186.54; 1.464 0.0028 0.0794 3.35 9.5 10 10 PTSA 6.051 6 FE34 MSA 186.06 1.460 0.00275 0.0794 3.36 9.5 10 10 PTSA 6.051 7 FE35 MSA 186.7 1.465 0.00299 0.0794 3.34 9.5 10 10 PTSA 6.051 8 FE-36 MSA 149.0 1.407 0.0027 0.3174 4.20 N/A 6 8 Note to NiPt etch rating: 1 = no NiPt removed; 10 = all of the NiPt was removed Note to Al corrosion rating: 1 = Al layer was completely removed or High Al ER; 10 = Low Al ER Note to Al pitting rating: 1 = Severe Al pitting; 10 = No Al pitting Note: Acidity contribution calculation for H⁺ for strong acids only (i.e. inorganic acid (1), inorganic acid (2), and MSA) assuming full ionization

Examples 9-17 and Examples C28-C43

Aluminum corrosion and NiPt etch responses were measured on the same type of substrates used in the earlier Examples. NiPt etch tests and aluminum corrosion tests were performed as outlined in General Procedure 2 and 3. Substrate coupons were immersed into the etch compositions heated to 50° C. for 1 or 2 minutes for NiPt etch tests and for 5 minutes for Al corrosion tests. Etch efficiency was gauged by the amount of NiPt residues left on top of dense gate line arrays and aluminum corrosion by the etch rate of aluminum and the severity of pitting on aluminum surface. Results are given in Table 4.

TABLE 4 NiPt Etch and Al Corrosion Responses at varying Cl⁻, NO₃ ⁻, H⁺, Water and Halide source concentrations Total H⁺ Total Cl⁻ or Total NO₃ ⁻ Total NiPt Al Corrosion Example Formula- Amount Br⁻Amount Amount Water Etch and Pitting # tion # [moles] [moles] [moles] Moles (1 to 10) (1 to 10) C28 CFE14 0.441 0.603 0.222 7.55 3 7 C29 CFE15 0.441 0.988 0.222 5.21 3 6 C30 CFE16 0.090 0.011 0.0794 10.811 2 9 C31 CFE17 2.22 0.011 2.21 3.35 10 1 C32 CFE18 0.914 0.000 0.222 6.64 1 10 C33 CFE19 0.979 0.219 0.000 6.61 1.5 9 C34 CFE21 0.979 0.219 0.222 7.02 10 8 C35 CFE22 0.845 0.219 0.222 7.73 8 6 C36 CFE24 0.980 0.219 0.159 6.90 10 7 C37 CFE26 0.979 0.219 0.079 6.76 10 8 C38 CFE28 0.710 0.603 0.222 6.12 9.5 6 C39 CFE29 1.595 0.219 0.222 3.73 10 7.5 C40 CFE30 0.947 0.110 0.222 6.83 9.5 7 C41 CFE31 0.813 0.110 0.222 7.55 5 9 C42 CFE33 0.978 0.110 0.111 4.38 9 6 C43 CFE41 0.0821 0.0027 0.0794 10.83 1 10  9 FE7 1.47 0.011 0.0158 3.35 10 9.5 10 FE8 1.49 0.011 0.0794 3.35 10 9 11 FE11 1.32 0.011 0.0795 4.24 10 6 12 FE12 1.66 0.011 0.0795 2.46 10 10 13 FE14 1.99 0.011 0.0795 0.687 8.5 10 14 FE16 1.68 0.011 0.635 3.35 10 8.5 15 FE17 1.49 0.0055 0.0795 3.34 10 9.5 16 FE18 1.49 0.0028 0.0795 3.34 9.5 9.5 17 FE19 1.57 0.0028 0.317 3.34 10 9 Note to NiPt etch rating: 1 = no NiPt removed; 10 = all of the NiPt was removed Note to Al corrosion and pitting rating: 1 = Al layer was completely removed or High Al ER or Severe Al pitting; 10 = Low Al ER and no Al pitting Note: Acidity contribution calculation for H⁺ for contribution of all strong acids assuming full ionization

The comparative formulations in Tables 3 and 4, including a few prior art compositions, contain a variety of chloride and nitrate sources in a range of concentrations and solvent. None of the comparative formulation in Tables 3 and 4 simultaneously achieved a high NiPt etch rate (defined by a rating of at least 8.5) and a high aluminum compatibility (defined as a rating of at least 8.5 in aluminum corrosion and pitting). (For Table 3 compositions, the Al compatibility rating is the average of the corrosion and pitting ratings.) Surprisingly, the compositions in Examples 1-7, 9, 10, and 12-17 containing a low level of chloride level (i.e., lower than 0.5% of chloride), a low to medium level of nitrate, at least one sulfonic acid, and water met these difficult, balanced criteria. In addition, as shown in Examples 4 and 5, inclusion of a second sulfonic acid having higher hydrophobicity (i.e., PTSA) than the first sulfonic acid (i.e. MSA) improved aluminum compatibility.

Examples 18-49 and Examples C44-C70 Evaluation of Etching Formulations for NiPt Etch, Al Compatibility and NiPtSi Oxidization

In order to better understand the effect of main components of etch compositions of this disclosure on NiPt etch and aluminum corrosion and NiPtSi oxidization, the main component concentrations were varied and evaluated. NiPt etch and aluminum corrosion were measured on the same type of substrates used in the earlier Examples C1-43 and Examples 1-17. NiPtSi oxidization responses were measured on the substrates containing ˜22 nm NiPtSi on silicon substrate and were either undoped (Table 5A), or n- or p-doped (Table 5B).

NiPt etch tests and aluminum corrosion and NiPtSi oxidization tests were performed as outlined in General Procedures 2, and 3 and the results were analyzed as described below and in General Procedure 4. Substrate coupons were immersed into the etch compositions heated to 50° C. for NiPt etch and aluminum corrosion tests for 2 and 5 minutes separately and then heated to 80° C. for NiPtSi oxidization tests for 30 minutes. Etch efficiency was gauged by the amount of NiPt residues left on top of dense gate line arrays and aluminum corrosion by the etch rate of aluminum and the severity of aluminum surface pitting and NiPtSi oxidization by the extent of sheet resistance change on processed NiPtSi substrates. Results are given in Tables 5A and 5B.

TABLE 5A Ratings for Etchant Formulations in NiPt Etch, Aluminum Compatibility and (Undoped) NiPtSi Oxidation Total Al Cl⁻ or Total Total Corrosion NiPtSi (undoped) Oxidization Total H⁺ Br− NO₃ ⁻ Water NiPt and (1 to 10) Example Formula- Amount Amount Amount Amount Etch Pitting blanket SEM- ESCA - # tion # [moles] [moles] [moles] [moles] (1 to 10) (1 to 10) ΔRs pad ∘ profile C44 CFE18 0.914 0.000 0.222 6.64 1 10 7.5 N/A N/A C45 CFE19 0.979 0.219 0.000 6.61 1.5 9 7.5 N/A N/A C46 CFE21 0.979 0.219 0.222 7.02 10 8 3 1 1 C47 CFE22 0.846 0.219 0.222 7.73 8 5 5 N/A N/A C48 CFE23 0.896 0.166 0.222 7.28 9 3 5 N/A N/A C49 CFE24 0.980 0.219 0.159 6.90 10 7 3.5 N/A N/A C50 CFE25 0.916 0.219 0.159 7.24 9.5 7 3 N/A N/A C51 CFE26 0.980 0.219 0.080 6.76 10 8 3 N/A N/A C52 CFE27 0.838 0.219 0.080 7.52 5 7 3.5 N/A N/A C53 CFE29 1.595 0.219 0.222 3.73 10 7.5 6.5 N/A N/A C54 CFE30 0.947 0.110 0.222 6.83 9.5 7 5 N/A N/A C55 CFE31 0.813 0.110 0.222 7.55 4 9 5 N/A N/A C56 CFE32 0.980 0.110 0.158 6.53 10 8.5 5.5 N/A N/A C57 CFE33 0.978 0.110 0.111 4.38 9 6 6.5 N/A N/A C58 CFE34 1.54 0.110 0.159 3.53 10 8 5.5 5 N/A C59 CFE35 1.49 0.110 0.0159 3.53 10 N/A 5 N/A N/A C60 CFE36 2.074 0.011 0.0795 0.119 3 N/A 10 N/A N/A C61 CFE37 2.01 0.011 1.5865 3.35 10 5.5 8 4 N/A C62 CFE38 1.47 0.0548 0.0795 3.45 9 4 9.5 N/A 7 (Br⁻) C63 CFE39 1.49 0.011 0.0795 3.38 9.5 5.5 N/A N/A N/A (Cl⁻ + 0.011 (Br⁻) C64 CFE41 0.0821 0.0027 0.0794 10.83 1 10 10 N/A N/A C65 CFE42 1.399 0.0402 0.3175 4.2 10 4 4 5 2 18 FE6 1.52 0.0274 0.159 3.38 10 9 7 6 N/A 19 FE7 1.47 0.011 0.0159 3.35 10 8.5 7.5 6 2 20 FE8 1.49 0.011 0.0795 3.35 10 9 7.5 6.5 3 21 FE11 1.32 0.011 0.0795 4.24 10 5.5 6.5 7 2 22 FE12 1.66 0.011 0.0795 2.46 9.5 10 8.5 6.5 N/A 23 FE13 1.82 0.011 0.0795 1.58 9 10 9 7.5 6 24 FE14 1.99 0.011 0.0795 0.687 8 10 9.5 7.5 7 25 FE15 1.57 0.011 0.3173 3.35 10 9 8 N/A 2.5 26 FE16 1.68 0.011 0.635 3.35 10 7.5 8 4 N/A 27 FE17 1.49 0.0055 0.0795 3.34 10 9.5 8 7 6 28 FE18 1.49 0.0028 0.0795 3.34 9.5 9 5 6.5 7 29 FE19 1.57 0.0028 0.317 3.34 10 8.5 8 4 8.5 30 FE21 1.49 0.0016 0.0795 3.34 9.5 N/A N/A 6.5 6 31 FE22 1.48 0.0005 0.0795 3.33 9 N/A N/A 7 N/A 32 FE23 1.48 0.011 0.0795 3.36 8 5.5 N/A N/A N/A (Br⁻) 33 FE26 1.434 0.0028 0.0794 3.37 9.5 N/A 8.5 7 7.5 34 FE27 1.464 0.0028 0.0794 3.35 9.5 10 8.5 7 9 35 FE28 1.476 0.0028 0.0794 3.35 9 N/A 8 N/A 7.5 36 FE29 1.482 0.0028 0.0794 3.31 9.5 N/A N/A 6 N/A 37 FE30 1.518 0.0028 0.0794 3.11 9 N/A N/A 4 N/A 38 FE31 1.486 0.0028 0.0794 3.32 9 10 8.5 6 9 39 FE32 1.426 0.0028 0.0794 3.34 9 N/A N/A 6 8.5 40 FE33 1.407 0.0028 0.0794 3.11 9 N/A N/A 8 N/A

TABLE 5B Ratings for Etchant Formulations in NiPt Etch, Aluminum Compatibility and (Doped) NiPtSi Oxidation Total Al NiPtSi (n-doped) NiPtSi Cl⁻ or Total Total Corrosion Oxidization (p-doped) Total H⁺ Br− NO₃ ⁻ Water NiPt and (1 to 10) Oxidization Example Formula- Amount Amount Amount Amount Etch Pitting ESCA ∘ blanket (1 to 10) # tion # [moles] [moles] [moles] [moles] (1 to 10) (1 to 10) SEM profile ΔRs SEM C66 CFE21 0.979 0.219 0.222 7.02 10 8 1 1 N/A N/A C67 CFE42 1.399 0.0402 0.3175 4.2 9.5 4 2 TBD 1 C68 CFE43 1.418 0.0402 0.0794 3.35 N/A 2 N/A N/A 1 N/A C69 CFE44 0.476 1.186 0.476 4.78 1 1 1 N/A N/A N/A C70 CFE45 1.360 0.0549 0.159 3.78 N/A 4 N/A N/A 1 N/A 41 FE18 1.49 0.0028 0.0795 3.34 9.5 9 N/A 5 6 N/A 42 FE27 1.464 0.0028 0.0794 3.35 9.5 10  5 7 8 5 43 FE29 1.482 0.0028 0.0794 3.31 9.5 N/A 5 6 N/A 5 44 FE30 1.518 0.0028 0.0794 3.11 9 N/A 4 8.5 N/A 4 45 FE31 1.486 0.0028 0.0794 3.32 9 10  N/A 8.5 N/A N/A 46 FE32 1.426 0.0028 0.0794 3.34 9 N/A 5 8 N/A 5 47 FE33 1.407 0.0028 0.0794 3.11 9 N/A 5 7 N/A 5 48 FE36 1.407 0.0027 0.3174 4.20 N/A 7 N/A N/A 4 N/A 49 FE37 1.538 0.0027 0.0794 3.11 9.5 N/A 7 8.5 N/A N/A Note to NiPt etch rating: 1=no NiPt removed; 10=all of the NiPt was removed Note to Al corrosion and pitting rating: 1=Al layer was completely removed or High Al ER and Severe Al pitting; 10=Low Al ER and no Al pitting Note to NiPtSi oxidization rating: 1=Highest NiPtSi sheet resistance change; 10=Lowest NiPtSi sheet resistance change Note to ESCA rating: 1=Highest NiPtSi oxygen profile; 10=Lowest NiPtSi oxygen profile Note to SEM Pad rating: 1=Lowest NiPtSi contrast uniformity; 10=Highest NiPtSi contrast uniformity Note: N/A=data not available Note: Acidity contribution calculation for H⁺ for contribution of all strong acids assuming full ionization The above notes apply to both Tables 5A and 5B.

The data in Tables 3, 4, 5A and 5B show that the compositions of this disclosure, in general, surprisingly outperformed comparative compositions in one or more areas without significant underperformance in other critical areas in multiple environments. A lower Cl⁻ concentration (e.g., less than 0.5% of chloride) and/or a lower NO₃ ⁻ concentration in the etch compositions of this disclosure generally resulted in a decrease of Al corrosion and NiPtSi oxidization. Formulations can be adjusted to give optimum results for etching depending on the specific metals present.

In addition, the results showed that using a mixture of a short chain alkylsulfonic acid (i.e., the first sulfonic acid) in combination with a more hydrophobic sulfonic acid (i.e., the second sulfonic acid) can have additional beneficial effects in decreasing Al corrosion and NiPtSi oxidation. Specifically, comparison of the ESCA oxidation ratings of FE15, FE18, FE26-FE28, FE31, and FE32, which have the same Cl⁻:nitrate ratio, shows that the formulations containing the above first and second sulfonic acids have higher oxidation ratings (i.e., less oxidation) than the samples without the second sulfonic acid.

Several comparative examples demonstrated the importance of specific components and/or ranges. For example, the results for Comparative Formulations CFE18 and CFE19 show that the absence of a halide or nitrate source produced low NiPt Etch rates. See, e.g., Comparative Examples C32 and C33. In addition, low halide and nitrate containing compositions likewise have low NiPt Etch rates, unless significant amounts of sulfonic acid are present in the formulation. See, e.g., Comparative Example C16. Comparison of formulations FE8, FE11, FE13, and FE14 (all having the same Cl⁻:nitrate ratio) shows that increasing the sulfonic acid content increases the blanket and ESCA oxidation rating (i.e., lower NiPtSi oxidation). See, e.g., Examples 20, 21, 23, and 24. Low halide and nitrate containing compositions also require at least a certain minimum level of water (e.g., at least about 3% of water) or the NiPt etch rate stays low. See, e.g., Example C60. Therefore, it is critical that all components required (i.e., at least one halide source, at least one nitrate source, at least one sulfonic acid, and water) are present and that a balance between these components (e.g., about 0.01%-0.5% chloride, about 0.1%-20% nitrate, and about 60%-95% sulfonic acid) is reached to achieve satisfactory NiPt etch rates, low metal corrosion, and low silicide oxidation.

TABLE 6 Other Material Compatibility with NiPt Etching Formulations Formulation # CFE21 FE18 FE18 CFE40 Etching 50/2 50/2 30/2 30/2 Temperature C./Time (min) NiPtSiC* 23.3 0.4 0.3 40.2 NiPtSiGe* 0.6 0.1 0.1 2.1 Etching 50/5 50/5 30/5 30/5 Temperature C./Time (min) TaN** 0.1 0.0 0.3 0.1 HfO₂** 0.3 0.1 0.2 0.1 SiO₂** 1.0 1.0 1.0 1.0 SiN** 0.1 0.1 0.0 0.2 W** 21.3 0.0 0.1 63.5 TiN** 1.5 0.2 0.1 4.4 *ΔSheet Res [mΩ/sq]; **Etching rate [Å/min]

In addition, Formulation FE18 and Comparative Formulations CFE21 and CFE40 were tested under different conditions for their compatibility with materials that may be present when etching a metal substrate in a semiconductor device by using General Procedure 3. The results are summarized in Table 6.

As shown in Table 6, FE18 (i.e., a composition of this disclosure) performed significantly better than Comparative Formulations CFE21 and CFE40 in these compatibility tests.

Examples 50 to 60 Evaluation of Etching Formulations for NiPt Etch, Al Compatibility and NiPtSi Oxidization

The etching formulations below are prepared according to General Procedure 1.

TABLE 7 Etching Compositions Total Acid Halide Other Halide Other Nitrate Water Water in Example compound/ Nitric Acid/ Source/ source/ Sulfonic Acid/ Added all sources # Amount [g] Amount [g] Amount [g] Amount [g] Amount [g] [g] (g) 50 none HNO₃ 7.143 NH₃(CH₃)Cl 0.185 none MSA 186.62 60.13 PTSA 6.051 51 HCl 0.054 HNO₃ 7.143 NiCl₄ 0.135 none MSA 171.62 15.0 70.67 PTSA 6.051 52 none HNO₃ 14.286 NiCl₄ 0.135 none MSA 102 83.58 118.47 53 HCl 0.30 None TMACl 0.150 TMANO₃ 10.79 MSA 179.37 3.34 59.34 PTSA 6.051 54 HBr 0.222 HNO₃ 7.143 MSA 186.58 60.12 PTSA 6.051 55 HCl 0.054 None none NH₄NO₃ 19.05 MSA 180.91 54.27 56 HCl 0.27 HNO₃ 7.143 ESA 134.68 57.91 60 57 HCl 2.7 HNO₃ 7.143 PTSA 190.16 66.59 58 HCl 0.27 HNO₃ 7.143 TFMSA 132.59 60 62.31 59 HCl 0.27 HNO₃ 7.143 MSA 186.58 58.76 NSA 6.051 60 HCl 0.27 (NO)BF₄ 9.27 MSA 183.46 7 7.17 (100%) Notes: Hydrochloric acid (HCl) is a 37% hydrochloric acid solution; Hydrobromic Acid (HBr) is a 48% acid solution; Nitric acid (HNO₃) is a 70% nitric acid solution; MSA is methanesulfonic acid which is a 70% methanesulfonic acid solution unless otherwise noted; PTSA is a 67% p-toluenesulfonic acid aqueous solution; ESA is a ethanesulfonic acid neat; TFMSA is a neat liquid containing trifluormethanesulfonic acid; NSA is 2-naphthalenesulfonic acid monohydrate; TMACl is a tetramethylammonium chloride anhydrous solid; TMANO₃ is a tetramethylammonium nitrate anhydrous solid; NH₄NO₃ is ammonium nitrate anhydrous solid. N(CH₃)H₃Cl is methylammonium hydrochloride solid; NiCl₄ is nickel tetrachloride solid. In addition, the amount for each component in this table refers to the amount of the component as added to the composition, not the amount of the active ingredient in the component. For example, 2.7 g of HCl in Example 57 refers to 2.7 g of a 37% hydrochloric acid solution, not 2.7 g of pure HCl.

The formulations are tested using General Procedures 2-4. The formulations are expected to have a high NiPt etch rate, low aluminum etch rate, and minimal to acceptable degrees of oxidation of undoped, p-doped, and n-doped NiPt Silicide.

Due to the reactive nature of the compositions in this disclosure, a method of formulating two components that would be mixed together and then heated at point of use to give the final etching composition is preferred. This type of partitioning of the composition is done to separate the reactive chloride and nitrate components to improve shelf and storage life of the etching solutions. Depending on the final formulation, the partitioning into two mixtures, which upon mixing in a predetermined ratio gives the final formulation, can be accomplished in various ways. Two examples are shown below:

Example 61 FE18

FE18 Final Formulation Components [wt %] FE18 Hydrochloric acid  0.05% Nitric acid  2.5% Methane sulfonic acid 67.41% Water 30.04% Total [wt %] 100.00% 

Two Component Mixing Method for Example 61 FE18; 1:1 Weight Mix A:B Component A Component B HCl 0.100% 0.000% HNO₃ 0.000% 5.000% MSA 69.811% 65.000% Water 30.089% 30.000%

Example 62 FE27

FE-27 Final Formulation Components [wt %] FE27 Hydrochloric acid  0.05% Nitric acid   2.5% Methane sulfonic acid 65.287% p-Toluenesulfonic Acid  2.00% Water  30.16% Total [wt %] 100.00%

Two Component Mixing Method for Example 62 FE-27; 1:1 Weight Mix A:B Component A Component B HCl  0.100%  0.000% HNO₃  0.000%  5.000% MSA 69.811% 60.760% p-Toluenesulfonic Acid  0.00%  4.00% Water 30.089% 30.240%

Examples 63 and 64 Evaluation of an Etching Formulation on Au and Pd

Films of Au on a Si substrate (Example 63) and Pd on a Si substrate (Example 64) are etched according to procedures in General Procedure 2 using formulation FE15. The Au and Pd films are expected to exhibit a high etch rate when etched by formulation FE15.

While the present disclosure has been described herein with reference to the specific embodiments thereof, it will be appreciated that changes, modification and variations can be made without departing from the spirit and scope of the inventive concept disclosed herein. Accordingly, it is intended to embrace all such changes, modification and variations that fall with the spirit and scope of the appended claims. 

What is claimed is:
 1. A kit for facilitating etching of NiPt during manufacturing a semiconductor device, comprising: at least one sulfonic acid in a first container; at least one compound containing a halide anion in a second container, the halide anion being chloride or bromide; and at least one compound containing a nitrate or nitrosyl ion in a third container; wherein the second container is different from the third container and wherein the kit is essentially free of thiocarbonyl compounds.
 2. The kit of claim 1, wherein the first container is the same as the second or third container.
 3. The kit of claim 1, wherein the first container is different from the second and third containers.
 4. The kit of claim 1, wherein the kit further comprises an instruction for mixing the at least one sulfonic acid, the at least one compound containing the halide anion, and the at least one compound containing a nitrate or nitrosyl ion to prepare an etching composition.
 5. The kit of claim 1, wherein the third container contains a nitrosyl ion.
 6. The kit of claim 1, wherein, after mixing the contents in the first, second, and third containers to form a mixture, the mixture comprises the at least one sulfonic acid, the halide ion, and the nitrate or nitrosyl ion at a weight ratio of about 25 to about 95:about 0.01 to about 0.5:about 0.1 to about
 20. 7. The kit of claim 1, wherein the at least one sulfonic acid comprises a compound of formula (1): R¹SO₃H  (1), in which R¹ is substituted or unsubstituted C₁-C₁₂ linear or branched alkyl, substituted or unsubstituted C₃-C₁₂ cyclic alkyl, C₁-C₁₂ linear or branched fluoroalkyl ether, or C₃-C₁₂ cyclic fluoroalkyl ether.
 8. The kit of claim 7, wherein R¹ is C₁-C₁₂ linear or branched alkyl or C₃-C₁₂ cyclic alkyl, each of which is optionally substituted with halogen, C₁-C₄ alkyl, sulfonic acid, or phenyl optionally substituted with C₁-C₄ alkyl or hydroxy.
 9. The kit of claim 8, wherein the at least one sulfonic acid is methanesulfonic acid.
 10. The kit of claim 1, wherein the at least one sulfonic acid comprises a compound of formula (2):

in which each of R², R³, and R⁴, independently, is C₁-C₁₂ linear or branched alkyl, C₃-C₁₂ cyclic alkyl, F, Cl, Br, OH, NO₂, SO₃H, or CO₂H; R⁵ is H; and each of a, b, c, and n, independently, is 0, 1, 2, or 3 provided that the sum of a, b, and c is n.
 11. The kit of claim 10, wherein each of R², R³, and R⁴, independently, is C₁-C₂ alkyl, Cl, NO₂, OH, F, or CO₂H; and n is 0 or
 1. 12. The kit of claim 1, wherein the at least one sulfonic acid comprises a naphthalenesulfonic acid optionally substituted with C₁-C₁₂ linear or branched alkyl or SO₃H.
 13. The kit of claim 1, wherein the first container comprises a first sulfonic acid and a second sulfonic acid.
 14. The kit of claim 13, wherein the first sulfonic acid comprises a compound of formula (1): R¹SO₃H  (1), in which R¹ is unsubstituted C₁-C₄ linear or branched alkyl.
 15. The kit of claim 14, wherein the second sulfonic acid comprises a compound of formula (2):

in which each of R², R³, and R⁴, independently, is C₁-C₁₂ linear or branched alkyl, C₃-C₁₂ cyclic alkyl, F, Cl, or Br; R⁵ is H; and each of a, b, c, and n, independently, is 0, 1, 2, or 3 provided that the sum of a, b, and c is n.
 16. The kit of claim 13, wherein the second sulfonic acid comprises a compound of formula (1): R¹SO₃H  (1), in which R¹ is substituted or unsubstituted C₆-C₁₂ linear or branched alkyl, substituted or unsubstituted C₆-C₁₂ cyclic alkyl, C₁-C₁₂ linear or branched perfluoroalkyl, C₃-C₁₂ cyclic perfluoroalkyl, C₁-C₁₂ linear or branched fluoroalkyl ether, C₃-C₁₂ cyclic fluoroalkyl ether, or substituted or unsubstituted C₇-C₁₂ alicyclic groups.
 17. The kit of claim 13, wherein the second sulfonic acid comprises a naphthalenesulfonic acid optionally substituted with C₁-C₁₂ linear or branched alkyl or SO₃H.
 18. The kit of claim 1, wherein the at least one compound containing a halide ion comprises hydrogen chloride, hydrogen bromide, ammonium chloride, ammonium bromide, a quaternary ammonium chloride, a quaternary ammonium bromide, an amine hydrochloride, an amine hydrobromide, a nitrogen based aromatic and pseudoaromatic hydrochloride, a nitrogen based aromatic and pseudoaromatic hydrobromide, a phosphonium chloride, a phosphonium bromide, a metal chloride, or a metal bromide.
 19. The kit of claim 18, wherein the at least one compound containing a halide ion comprises hydrogen chloride, ammonium chloride, ammonium bromide, or a quaternary ammonium chloride.
 20. The kit of claim 1, wherein the at least one compound containing a nitrate or nitrosyl ion comprises nitric acid, ammonium nitrate, a quaternary ammonium nitrate, a substituted ammonium nitrate, a nitrogen based aromatic and pseudoaromatic reaction product with nitric acid, a phosphonium nitrate, a metal nitrate, nitrosyl chloride, nitrosyl bromide, nitrosyl fluoride, nitrosyl tetrafluoroborate, or nitrosyl hydrogen sulfate.
 21. The kit of claim 20, wherein the at least one compound containing a nitrate or nitrosyl ion comprises nitric acid. 